Food substance heating and dispensing system

ABSTRACT

A dispensing system for heating and dispensing a food substance in a liquid state includes a portable dispensing unit including housing comprising a reservoir for holding a food substance, a heater operable to heat the substance to an operating temperature for producing a liquid, and a pump for dispensing the liquid via a dispensing tube and spray nozzle. A manually activated actuator operates to initiate the dispensing cycle. Control circuitry associated with the dispensing unit monitors the liquid temperature and controls operation of pump and unit. The dispensing unit may be powered by a rechargeable battery. A charging base provides a dock for recharging the battery of the dispensing unit. The pump may include an auto-reverse feature to draw the liquid back into reservoir when not dispensing the liquid for preventing clogs in the dispensing system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Chinese Utility Model ApplicationNo. 2018920107183.0 filed Jan. 22, 2018, which is incorporated herein byreference in its entirety.

BACKGROUND

The present invention relates generally to apparatuses and processes forheating and dispensing a normally viscous or at least partially solidedible food substance.

Dairy products such as butter have many uses associated with thepreparation of food. As some examples, butter may be used as a condimentto enhance flavor, as an additive incorporated into a cake batter forbaking, or alternatively as a dairy-based source of fat, which can beused for frying. Various approaches have been used for heating andmelting butter to convert this normally semi-solid/solid substance (i.e.at least partially solid) at typical ambient room temperatures (e.g.about 73 degrees F.) into a liquid state or condition amenable to manyuses. It is desirable to use butter in liquid spray form in manyapplications.

Improved systems and processes which combine the functions of meltingand dispensing a food substance such as butter are desired.

BRIEF SUMMARY

Embodiments according to the present disclosure provide a dispensingsystem and related processes or methods operable for storing, meltingand dispensing an at least partially solid edible food product orsubstance in a liquid state. In various embodiments, the dispensingsystem may be configured to self-clean the dispensing tube, and/or heatthe dispensing tube and associated dispensing nozzle to prevent theliquid from solidifying and clogging the dispensing flow path. In someembodiments, the system includes a control circuit configured such thatthe dispensing mechanism cannot be actuated to dispense the foodsubstance until the circuit detects that the food substance hassufficiently melted and attained a liquid state of suitable temperatureand viscosity amenable for pumping and spraying. This further reducesthe likelihood of clogs or poor spray-ability and spray pattern due tothe liquified food substance being more viscous than desired for optimaloperation of the dispensing mechanism. In one embodiment, the dispensingmechanism may be configured to spray the food substance in the liquidstate to produce a relatively fine mist. In addition, embodiments of thepresent dispensing system may be used for heating non-solid viscous foodsubstances or fluids such as cooking oils to decrease their viscosityand improve spray-ability. Accordingly, the present apparatus is usablewith either viscous or at least partially solid substances amenable toheating to decrease viscosity and/or change state from solid to liquidform as applicable.

The edible food substance usable with the present apparatus may bebutter in some applications; however, other food products having similarcharacteristics to butter which are transformable from an at leastpartially solid state into a liquid state when heated may be used withthe apparatus in addition to viscous fluids which are not at leastpartially solid at typical ambient room temperatures. Accordingly, thetype of food substance used does not necessarily limit the applicabilityand use of the heating and dispensing system described herein.

In one aspect, a system for heating and dispensing a food substance in aliquid state includes a dispensing unit comprising: an elongated housingdefining a longitudinal axis; a reservoir disposed in the housing andconfigured for receiving a food substance; an arcuately curved heatingband complementary configured to the reservoir and in conformal contactwith exterior side surfaces of the reservoir, the heating band operableto melt the food substance therein to produce a liquid; the heating bandextending for substantially an entire height of the reservoir andwrapping around a circumference of the reservoir; a pump in fluidcommunication with the reservoir for pumping the liquid; a power supply;an actuator configured to selectively activate the pump; a dispensingnozzle supported by the housing; and a dispensing tube fluidly couplingthe pump to dispensing nozzle; wherein activating the pump dispenses theliquid from the reservoir through the dispensing tube and nozzle.

In another aspect, a system for heating and dispensing a food substancein a liquid state includes: a housing defining a longitudinal axis; areservoir disposed in the housing and configured for receiving a foodsubstance; a heater in thermal contact with the reservoir and operableto melt the food substance therein to produce a liquid; a pump in fluidcommunication with the reservoir for pumping the liquid; a power supply;an actuator configured to selectively activate the pump, the actuatorbeing alterable between an actuated and a deactuated state; a dispensingnozzle supported by the housing; a dispensing tube fluidly coupling thepump to the dispensing nozzle; a temperature sensor operable to measurea temperature of the liquid in the reservoir; and control circuitryoperably coupled to the temperature sensor and pump; wherein placing theactuator in an actuated state activates the pump and dispenses theliquid from the reservoir through the dispensing tube and nozzle;wherein the control circuitry is configured such that the pump cannot beactivated until the temperature reaches a preprogrammed minimum baselineoperating temperature.

In another aspect, a method for heating and dispensing a food substancein a liquid state includes: providing a dispensing unit comprising ahousing, a reservoir for receiving a food substance in at leastpartially solid form, a heating band, a pump fluidly coupled to thereservoir, and control circuitry operably coupled to the pump andheating band; inserting the food substance into the reservoir; heatingthe food substance with the heating band to produce a liquid; measuringa temperature of the liquid with a temperature sensor operably coupledto the control circuitry; depressing an actuator on the dispensing unit;activating the pump which rotates in a first direction; and the pumpdispensing the liquid from the reservoir through a dispensing tube;wherein the control circuitry is configured to prevent activating thepump until the temperature reaches a minimum baseline operatingtemperature preprogrammed into the control circuitry.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein likeelements are labeled similarly and in which:

FIG. 1 is a perspective view of a system for heating and dispensing aliquefied food substance according to the present disclosure including adispensing unit and a charging base;

FIG. 2 is a rear perspective view thereof;

FIG. 3 is a bottom perspective view thereof;

FIG. 4 is an exploded perspective view thereof;

FIG. 5 is an exploded perspective view of the dispensing unit alone;

FIG. 6 is a top view of the system of FIG. 1;

FIG. 7 is a bottom view thereof;

FIG. 8 is a rear elevation view thereof;

FIG. 9 is a front elevation view thereof;

FIG. 10 is a right side elevation view thereof;

FIG. 11 is an exploded perspective view of the charging base;

FIG. 12 is a bottom perspective view of the dispensing unit aloneshowing the electrical connector for connection with the electricalconnector of the charging base seen in FIG. 11;

FIG. 13 is a longitudinal cross-sectional view of the dispensing unit;

FIG. 14 is a first enlarged view thereof showing the upper portion indetail;

FIG. 15 is a second enlarged view thereof showing the dispensing portionin detail;

FIG. 16 is an exploded top perspective view of the dispensing unit;

FIG. 17 is an exploded bottom perspective view thereof;

FIG. 18 is an exploded view of the dispensing system and dispensing flowpath of the dispensing unit with covers and other appurtenances removedfor clarity;

FIG. 19 is an exploded perspective view of the dispensing nozzleassembly;

FIG. 20 is a top perspective view of the upper pump cover; and

FIG. 21 is a bottom perspective view thereof.

All drawings are schematic and not necessarily to scale.

DETAILED DESCRIPTION

The features and benefits of the invention are illustrated and describedherein by reference to exemplary embodiments. This description ofexemplary embodiments is intended to be read in connection with theaccompanying drawings, which are to be considered part of the entirewritten description. Accordingly, the disclosure expressly should not belimited to such exemplary embodiments illustrating some possiblenon-limiting combination of features that may exist alone or in othercombinations of features.

In the description of embodiments disclosed herein, any reference todirection or orientation is merely intended for convenience ofdescription and is not intended in any way to limit the scope of thepresent invention. Relative terms such as “lower,” “upper,”“horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and“bottom” as well as derivative thereof (e.g., “horizontally,”“downwardly,” “upwardly,” etc.) should be construed to refer to theorientation as then described or as shown in the drawing underdiscussion. These relative terms are for convenience of description onlyand do not require that the apparatus be constructed or operated in aparticular orientation. Terms such as “attached,” “affixed,”“connected,” “coupled,” “interconnected,” and similar refer to arelationship wherein structures are secured or attached to one anothereither directly or indirectly through intervening structures, as well asboth movable or rigid attachments or relationships, unless expresslydescribed otherwise.

As used throughout, any ranges disclosed herein are used as shorthandfor describing each and every value that is within the range. Any valuewithin the range can be selected as the terminus of the range. Inaddition, all references cited herein are hereby incorporated byreferenced in their entireties. In the event of a conflict in adefinition in the present disclosure and that of a cited reference, thepresent disclosure controls.

FIGS. 1-21 depict a dispensing system configured and operable forstoring, heating, and dispensing a liquefied food substance according tothe present disclosure. The dispensing system 100 in one non-limitingembodiment may generally include an assembly of a rechargeabledispensing unit 102 and charging base 104.

FIG. 11 is an exploded view of charging base 104 and FIG. 13 includes across-sectional view thereof. Base 104 may include in order an upperbase cover 110 and lower base cover 112 which define an internal basecavity 117. A power board 111 comprising electronic circuitry isdisposed in cavity 117 which is conductively connected to a power cable103 that provides power to the base for controlling the power supply andrecharging the dispensing unit 102. A power cable trim strip 115 securesthe power cable to the power board 111 such as via threaded fasteners117. A pin board 118 operably and electrically connected to the powerboard 111 in one non-limiting embodiment supports an elongated pincushion 114 and pin sealing rings 113; both of which receive and supporta plurality of metal contacts which may be in the form of verticallyelongated conductive pins 107. Pins 107 are received in an electricalterminal connector 105 which mates with contacts or pins of acomplementary configured connector 106 on the bottom of dispensing unit102 to transfer power from the base 104 to the control board 125 in thedispensing unit. Control board 125 includes a power distribution circuitelectrically connected to the rechargeable battery 101, pump motor 154,heating band 131, status lights 198, and other components on thedispensing unit 102 under the control of the control circuitry 126integrated into the control board, as further described herein. Othertypes, arrangements, and/or shapes of electrically conductive contactsand connectors may be used and does not limit the invention. Theelectrical power cable 103 includes a standard two or three-prong endplug which can be plugged into a standard electrical outlet as typicallyfound in a building structure. A charging base indicator light 200 whichmay be an LED (light emitting diode) is mounted on pin board 118 toprovide the operational status of the base (e.g. power on, dispensingunit 102 charging, etc.). An on/off switch 201 may be provided to powerthe unit on or off. The base upper and lower covers 110 and 112 may beformed of any suitable non-metallic (e.g. plastic) or metallicmaterials.

Dispensing unit 102 may be removably and electrically coupled to thebase 104 for recharging the dispenser battery 101 via electricalconnectors 105, 106. Battery 101 may be a rechargeable lithium battery101 in one example for operating the dispensing unit 102. Other types ofsuitable batteries for this application however may be used.

Referring generally again to FIGS. 1-18 at first, dispensing unit 102generally includes a main outer housing 120, a removable top cap orcover 123, and bottom cover 124. Outer housing 120 in one constructionmay include a front housing 121 and rear housing 122 attachable to thefront housing. Housing 120 may be vertically elongated and generallycylindrical in one configuration. Housing 120 defines a verticallongitudinal axis LA (reference made to dispensing unit in the uprightposition).

A control board 125 which may be printed circuit board (PCB) is disposedin housing 120 of dispensing unit 102. Control board 125 may be ofcircular shape (shown), or another shape such as without limitationrectilinear or polygonal. In one arrangement, control board 125 may bepositioned adjacent bottom cover 123.

Control board 125 includes control circuitry 126 which controlsoperation of the dispensing unit 102 for generally heating anddispensing the food substance, and control charging of the rechargeabledispensing unit 102. The control circuitry 126 comprises a programmablemicrocontroller (MCU) 126 a (schematically depicted in FIG. 5) operableto execute program instructions or code (e.g. control logic orsoftware). The microcontroller 126 a includes one or more processors(CPUs/MPUs), non-transitory tangible computer readable medium 126 b, andprogrammable input/output peripherals. Computer readable medium 126 bmay include volatile memory and non-volatile memory operably andcommunicably coupled to the processor(s). Any suitable combination andtypes of volatile or non-volatile memory may be used including asexamples, without limitation, random access memory (RAM) and varioustypes thereof, read-only memory (ROM) and various types thereof, flashmemory, or other memory which may be written to and/or read by theprocessor operably connected to the medium. Both the volatile memory andthe non-volatile memory may be used for storing the program instructionsor software. In some embodiments, the control circuitry 126 may be asystem on a chip (SOC) or an application-specific integrated circuit(ASIC) comprising a microchip; either of which may be designed andconfigured to control the dispensing unit 102 in accordance with thefunctions described herein.

The control circuitry 126 may further include an input/outputcommunication interface or module configured for wireless and/or wiredcommunication for programming the processor and exchanging data with thecontrol circuitry 126. Wireless communication protocols used may includeBluetooth, NFC (near field communication), WiFi, or others. The controlcircuitry 126 may include all the usual ancillary components necessaryto form a functional data processing and control device. It is wellwithin the ambit of one skilled in the art to provide and configure thecontrol circuitry with all the required appurtenances to provide a fullyfunction control system for operating the dispensing unit 126 in themanner disclosed herein. It will be appreciated that various aspects ofthe dispensing unit control and functionality may be embodied insoftware, firmware, or hardware.

Dispensing unit 102 further includes an internal assembly comprising aspray apparatus 130 which is configured and functions to store, heat,melt, and dispense the food substance in liquid form. Referringparticularly to FIGS. 13-21, spray apparatus 130 generally includes aliner or reservoir 131, a heater such as a flexible heating panel orband 132, a pump 133, dispensing nozzle assembly 134, actuator assembly138, and cover 135. Cover 135 may include a front cover 136 and rearcover 137 attachable to the front cover. The covers 136 and 137 may eachbe semi-circular in transverse cross section and formed as matinghalf-cylinders in one configuration. Covers 136, 137 may extend for amajority of, and more particularly in the illustrated embodiment,substantially the entire height of the reservoir 131.

To removably and sealably attach the top cover 123 of dispensing unit102 to the cover 137 of the spray apparatus 130, a threaded bottle ring170 may be disposed on the top end of the cover as shown in FIGS. 5 and16-17. The inside of the top cover 123 comprises complementaryconfigured threads. The threads on the bottle ring and top cover may bemutually configured for ¼ turn opening/closing operation of the topcover in one embodiment. Bottle ring 170 is sealed to the sprayapparatus cover 137 by a combination of a bottle seal ring 171 andreservoir seal ring 172, thereby forming a leak-resistant coupling. Thetop cover 123 of the dispensing unit is in turn fluidly sealed to bottlering 170 via a seal, which may comprise an assembly of cooperating firstand second annular seals 173 and 174 in one embodiment. Other methods ofattaching and sealing the top cover 123 to the top end of sprayapparatus 130 may be used.

Reservoir 131 includes an internal cavity 141 configured for holding andstoring the food substance FS, which in one non-limiting example may bebutter. In one embodiment, reservoir 131 may be formed by a verticallyelongated cylindrical shell 140 including an open top 142 for insertingthe food substance, and a substantially closed bottom 145 except for anoutlet opening 143 fluidly coupled to the pump suction coupling 146. Inone embodiment, reservoir 131 may be formed a metal such as withoutlimitation aluminum, stainless steel, or other suitable for being heatedby heating band 134.

In one embodiment, reservoir 131 may be configured and dimensioned toprovide a volumetric capacity capable of holding at least one standardstick of butter. A standard U.S. stick of butter weighs approximately 4ounces and has a rectangular cuboid shape measuring approximately 3.25inches long×1.5 inches high×1.5 inches wide. The reservoir has acommensurate height and diameter to at least accommodate thesedimensions, and in some embodiments has a height and diameter close tothese dimensions (but slightly larger of course) to minimize the overallheight and diameter of the dispensing unit making it compact andcomfortable for the user to grip.

Heating band 134 is operable to heat and melt the food substance FS inreservoir 13 to produce a liquid. Heating band 134 may be configured andarranged to engage the cylindrical exterior side surface of reservoir131 and is disposed between the cover 135 and reservoir. In oneembodiment, heating band 134 in particular may be arcuately curved andin conformal contact with a majority of, and preferably substantiallythe entirety of the exterior side surfaces of the reservoir 131 foreffective and efficient heating thereof. Heating band 134 iscomplementary configured to the reservoir and shares a similarvertically elongated cylindrical shape as shown. The heating band 134may extend for substantially the entire height of the reservoir 131 andwraps around a majority, and preferably the substantial entirety of acircumference of the reservoir. Heating band 134 has a monolithic solidstructure extending between a top end 139 a and a bottom end 139 b ofthe heating band.

Heating band 134 is formed of a resiliently deformable materialproviding a structure having an elastic memory. To increase flexibilityof the heating band 134, a linear slit 147 formed in the body of theheating band extends vertically between the top and bottom ends 139 a,139 b of heating band for the entire height of the band forming avertical part of the slit. The heating band 134 may include a horizontalbottom portion 148 which partially closes the bottom end 139 b of theband (best seen in FIG. 17). The slit 147 continues horizontally acrossand through this bottom portion 148 forming a horizontal part of slitwhich is contiguous with the vertical part of the slit.

Heating band 134 is changeable between an undeformed contracted stateand a deformed expanded state when positioned on and around thereservoir 131. The heating band 134 may have an undeformed diameterslightly smaller than the reservoir. To install the heating band 134which is initially in the undeformed contracted state prior to mountingon the reservoir, the band is slid onto the reservoir 131 from itsbottom end. Due to the differences in diameters between the band andreservoir, the heating band will expand and deform circumferentially viathe slit 147 when the band slideably engages the cylindrical sidesurfaces of the reservoir 131. The elastic memory of the heating band134 creates a clamping action on the reservoir 131 causing the heatingband to frictionally engage the reservoir. This creates a conformcontact between the heating band and reservoir with no substantialinterstitial spaces present between the band and reservoir for optimumheating efficiency. The heating band 134 will remain in this deformedexpanded state while position on reservoir 131.

Heating band 134 may be formed of a sufficiently thin metal plate whichis bent or otherwise formed to a cylindrical shape. Examples ofmaterials which may be used include electrically conductive metalspossessing an elastic memory to produce the resiliently deformablestructure, such as without limitation copper, aluminum, steel, or other.A pair of electrically conductive leads 149 electrically couples theheating band 134 to the power source (e.g. battery 101). In oneembodiment, the heating band 134 may be coupled to the power sourcethrough the control circuitry 126 which may be configured to control theheating of the food substance.

Pump 133 may be a positive displacement type pump. In one embodiment, aperistaltic pump as illustrated may be used which are well known in theart and commercially-available. Peristaltic pumps generally comprise aflexible flow tube disposed inside the pump casing which is acted uponby a rotating roller assembly that alternatingly compresses and relaxesthe tube to create negative pressure (vacuum) and positive pressureinside the flow tube. This draws or suctions liquid from a reservoirinto the pump under negative pressure, and discharges or displaces theliquid under positive pressure to the delivery site.

With reference to FIGS. 13-21, pump 133 generally includes a pumphousing comprising an upper cover 150 and lower foundation 153, rollerassembly 151, U-shaped flexible/resilient flow tube 152, and electricmotor 154. Cover 150 and foundation 153 are attached together such asvia fasteners 161 or other means (e.g. snap fit, interlockingtabs/slots, etc.), and collectively define an internal chamber 155 forhousing the roller assembly and flow tube therein. The cover 150 andfoundation 153 may each be considered generally disk-like andcylindrical in shape. The upper cover 150 attaches to the bottom end ofthe spray apparatus cover 135 and supports the reservoir 131 whichprojects upwardly therefrom.

The deformable resilient flow tube 152 remains stationary duringoperation of the pump and is fixedly mounted between the pump uppercover 150 and lower foundation 153. The roller assembly 152 is mountedon the spindle of the motor 154 and rotated by the motor. Rollerassembly 152 may comprise a plurality of rollers 151 (e.g. 3 rollers inthis non-limiting example) which engage and alternatingly compress andrelax/release the flow tube in typical fashion as the rollers rotate topump the liquefied butter from the reservoir 131. The rollers 151 act tocompress sections of the tube 152 against an arcuately curvedcompression wall 162 formed on the underside of the pump upper cover 150(see, e.g. FIG. 21). The clearance between the rollers 151 and wall 162therefore is less than the diameter of the flow tube 152. This squeezesand deforms the flow tube 152 to pump the liquid from the reservoir 131.The vertical centerline CL1 of the pump defined by the spindle of themotor 154 defines a rotational axis, which in some embodiments asillustrated may be laterally offset from longitudinal axis LA of thedispensing unit 102.

Flow tube 152 includes a suction coupling 146 on one end and a dischargecoupling 144 on the opposite end. Suction coupling 146 is fluidlycoupled to the reservoir 131 (i.e. cavity 141) via a suction nozzleassembly 158 on pump upper cover 150. The nozzle assembly 158 mayinclude a filter 163 to filter the liquid in addition to seals andfittings necessary to establish a leak-resistant fluid coupling betweentube suction coupling 146 and reservoir 131 via outlet opening 143 atthe bottom of the reservoir. Filter 163 may comprise a porous filtermedia or may include one or more holes of predetermined diameters toblock larger unmelted portions of the food substance or congealed butterfat in reservoir 131 from entering the pump suction. Cover 150 includesan inlet opening 164 establishing a flow passageway between thereservoir and pump inlet nozzle assembly 158. Discharge coupling 144 isfluidly coupled to a pump dispensing tube 160 via a discharge nozzle 159on pump upper cover 150 for dispensing the liquefied food substance fromthe pump 133.

Motor 154 may be mounted beneath the lower foundation 153 of pump 133.Foundation 153 may include a downward open motor chamber 156 configuredfor receiving the motor 154 at least partially therein. In a similarvane, the foundation may also define a downwardly open battery chamber157 for receiving the upper portion of the battery 101 at leastpartially therein. Each of the chambers 156 and 157 are complementaryconfigured to the motor 154 and battery 101, respectively, to securelyposition the motor and batter within the spray apparatus 130.

Both the pump upper cover 150 and lower foundation 153 may include oneor more other openings for forming electrical or control wiringconnections to the power supply (battery 101) and control board 125 inthe dispensing unit 102.

Pump dispensing tube 160 fluidly couples the pump discharge to thedispensing nozzle assembly 134. Tube 160 has a first end fluidly coupledto flow tube discharge coupling 144 and a second end fluidly coupled tothe nozzle assembly 134. Dispensing tube 160 may be L-shaped in oneembodiment and may have a substantially rigid structure as illustrated.The dispensing tube may thus include a long vertical section arrangedparallel to longitudinal axis LA and a shorter horizontal sectionoriented perpendicularly to the vertical section and longitudinal axis.

In one embodiment, the dispensing nozzle assembly 134 may comprise aninner nozzle 181 and an outer spray nozzle 182. Inner nozzle 181 isthreadably coupled to a threaded boss 180 formed on the front cover 136of spray apparatus 130 through which the shorter horizontal section ofdispensing tube 160 projects from the cover. Outer spray nozzle 182 isconfigured to produce a spray pattern and is threadably coupled to theinner nozzle. One or more annular seals 183 which may be O-rings may beprovided in the nozzle assembly 134 to form a leak-resistant fluid seal.The nozzle assembly 134 may include an orifice plate 184 to regulate theflow of the liquid food substance through the nozzle. In one embodiment,nozzle assembly 134 may be disposed proximate to the top of thedispensing unit 102 near top cover 123. The nozzle assembly 134 mayinclude a nozzle cover 185 and nozzle sponge 186 interposed between thecover 185 and front cover 136. Other arrangements and configurations ofthe dispensing nozzle assembly may be provided.

In one embodiment, the pump dispensing tube 160 is preferably formed ofa heat resistant metallic or non-metallic material (e.g. silicon,copper, stainless steel, etc.) capable of direct engagement with theheating band 134 for heating the tube. Tube 160 is interspersed betweenthe front cover 136 of spray apparatus 130 and heating band 134. In oneparticular embodiment, dispensing tube 160 may be arranged to abuttinglycontact heating band 134 for a majority of the vertical length or heightof the tube to be heated. This heating advantageously ensures that theliquid food substance is maintained in fluid form and does not solidifyeither when spraying or in between intermittent spraying operations toprevent clogging the dispensing tube. In one arrangement, the top end139 a of heating band 134 terminates at a point at least equal to orhigher than the horizontal section of the dispensing tube 160 (see, e.g.FIGS. 13-15). In one embodiment, the inner nozzle 181, outer spraynozzle 182, and threaded boss 180 of the dispensing nozzle assembly 134may further preferably be formed of a suitable metal as well to beconductively heated by the dispensing tube 160 for the same purposes.This ensures that the food substance remains completely melted and in aliquid state suitable for spraying in the entire dispensing system.

Referring generally to FIGS. 1-14, actuator assembly 138 includes adepressible actuator button 190, button holder 191 mounted on frontcover 136 of spray apparatus 130, and an actuator circuit board 192 alsomounted on the front cover. Button holder 191 movably supports theactuator button 190. The actuator circuit board 192 may be operably andcommunicably coupled to the main control board 125 and control circuitry126 via communication passageways which may comprises wired connectionsin one embodiment. The actuator circuit board 192 may include anelectronic or mechanical switch configured and operable to detectdepression of the actuator button 190 by a user dispense and spray theliquid food substance from reservoir 131. Detection of a depressedactuator button 190 transmits a control signal to control circuitry 126to actuate the pump 133 and initiate the dispensing/spraying action.

In one embodiment, the actuator button 190 may be positioned on thefront housing 122 of dispensing unit 102 below the dispensing nozzleassembly 134. The button 190 may protrude from beneath the front housingthrough an access opening 194 of suitable size and shape (see, e.g. FIG.5). Other arrangements and configurations of the actuator assembly 138are possible.

A control interlock may optionally be provided to prevent dispensing thefood substance until the at least partially solid substance (e.g.butter) is fully melted and ready for dispensing (i.e. in liquid form).This advantageously prevents or minimizes chances for clogging thedispensing tube 160 or dispensing nozzle assembly 134 with partiallysolidified or highly viscous food substance. In one embodiment, atemperature sensor 193 may be provided which is configured and arrangedto measure the real-time actual temperature of the food substance (e.g.butter) inside the reservoir 131. This may be achieved in oneimplementation by detecting the temperature of the inner wall ofreservoir 131 with the sensing portion or head of the temperature sensor193 based on the principle that the electrical resistance of a materialchanges with a corresponding change in temperature. FIG. 5 schematicallydepicts temperature sensor 193 as an L-shaped object (which is not to beliterally interpreted as such). Any suitable resistance measuring typetemperature sensor may be used, such as for example without limitation athermistor, thermocouple, RTD (resistance temperature detector), orother type temperature sensor. Temperature sensor 193 is operably andcommunicably coupled to the control circuitry 126 (e.g. via a wiredconnection leads).

Control circuitry 126 (e.g. microprocessor 126 a) in one embodiment ispreprogrammed with a minimum baseline operating temperature associatedwith the food substance, which may be stored in computer readable medium126 b (e.g. memory). The control circuitry 126 is configured to form anelectrical/electronic interlock with the pump motor 154 such that themotor and pump 133 cannot be started or actuated unless the real-timemeasured food substance temperature meets or exceeds the preprogrammedbaseline operating temperature. The baseline operating temperaturecorresponds to the desired or ideal temperature for dispensing the foodsubstance in liquid form (e.g. proper viscosity) to prevent clogging thedispensing mechanism.

The control circuitry 126 may further be operable to continuouslymaintain the temperature of the food substance FS in reservoir 131 at orabove the preprogrammed baseline operating temperature. For a variety offood substances such as butter, the viscosity varies proportionally totemperature. Accordingly, measuring actual temperature of the foodsubstance via temperature sensor 193 provides a corresponding indicationof its viscosity.

The dispensing unit 102 may further include a status indication systemwhich provides system status information to the user about the variousoperational stages of unit. The status indication system may beconfigured to provide visual and/or audible information and alerts tothe user. In one embodiment, referring to FIGS. 2, 5, and 14, a visualstatus indication system may include a control light display comprisinga status light board 195 including electronic circuitry and one or morecolor-changing status lights 198, such as without limitation LEDs (lightemitting diodes). In one embodiment, the light board 195 may be mountedinside the rear housing 121 of dispensing unit 102 adjacent to anelongated opening. A light guide ring 196 and clear or translucent trimstrip or lens cover 197 may be provided which are mounted on the rearhousing 121 adjacent the light board 195 to protect the LEDs whileallowing their visual observance by a user.

Operation of the status lights 198 may be controlled by main controlcircuitry 126 in cooperation with the light board 195 and temperaturesensor 193 previously described herein. Light board 195 therefore may beoperably and communicably coupled to the control circuitry 126 viacommunication passageways such as wiring. In one embodiment, temperaturesensor 193 (shown in FIG. 5) may be used to provide the followingtemperature-based information to the user via status lights 198:dispensing unit 102 status light RED flashing—remind user put dispensingunit on the base 104 to reheat the food substance; dispensing unitstatus light steady RED—the dispensing unit starts heating foodsubstance in reservoir 131; dispensing unit status light BLUEflashing—the user can use the dispensing unit to spray the foodsubstance; and dispensing unit status light steady BLUE—food substance(e.g. butter) is 100% melted. Numerous variations of the status lightoperation and signaling may be used including different and/oradditional status light indications.

A method for heating and dispensing a food substance in a liquid statewill now be briefly described. In this example process, the foodsubstance is at least partially solid food substance at typical ambientroom temperatures (e.g. approximately 73 degrees F.), such as withoutlimitation a stick or pieces of butter. It will be appreciated that theorder or sequence for performing the following steps may be rearrangedand changed. Accordingly, the variations in the sequence are possible.

The method comprises first removing the top cover 123, inserting thefood substance into the reservoir 131, and replacing the top cover. Thecharging base 104 may first be connected and plugged into an availableelectrical outlet if not already connected. The base indicator light 200(see, e.g. FIG. 2) may light steady “RED” to indicate the base isenergized. The dispensing unit 102 is then placed on the base 104, whichmay causes the base indicator light 200 to light steady “GREEN” if theunit is properly place on and electrically coupled to the base. Thistriggers the control circuitry 126 to automatically energize the heatingband 132. The status lights 198 of dispensing unit 102 may light steady“RED” initially to indicate that the dispensing unit has started theheating cycle to heat and melt the food substance forming a liquid.

Temperature sensor 193 continuously measures the real-time actualtemperature of the food substance in reservoir 131, which is monitoredby the control circuitry 126 and compared the preprogrammed minimumbaseline operating temperature as previously described herein. Thecontrol circuitry is configured to interlock and prevent the pump 133from being activated until the temperature reaches the preprogrammedminimum baseline operating temperature, as previously described herein.

Once the food substance reaches the preprogrammed minimum baselineoperating temperature indicating that the food substance (e.g. butter)has fully melted and is in liquid form at proper temperature ready fordispensing (e.g. minimum baseline operating temperature of 140 degreesF. in one non-limiting example), the dispensing unit status lights 198may light flashing “BLUE.” The control circuitry 126 may be configuredto continuously maintain the baseline operating temperature of 140degrees F. while the dispensing unit 102 remains attached to the base104. When the dispensing unit is removed, the control circuitry 126 maybe configured to de-energize the heating band 132 while the dispensingunit is in user by the user.

The dispensing unit 102 may then be removed from base 104 and used todispense/spray the liquid food substance via depressing the actuatorbutton 190 on the dispensing unit which activates and rotates the pump133 in a first dispensing direction. FIG. 18 shows the liquid dispensingflow path (see directional flow arrows). In one embodiment, thedispensing unit may be configured to operate such that continuouslyholding the button 190 down in a depressed position will continuouslyspray the liquid food substance. Releasing the button 190 stopsdispensing the liquid.

In some embodiments, releasing the actuator button 190 also mayautomatically trigger a pump auto-reverse feature. The control circuitry126 detects release of actuator button 190 after it has been depressedand stops the pump 133. The act of releasing the button 190 detected bythe control circuitry transmits a signal from the circuitry to run thepump 133 for a preprogrammed short time duration in a second reversedirection such as via reversing rotation of the motor whose operation iscontrolled by the circuitry. This creates a vacuum which draws theliquid within the dispensing tube 160, nozzle assembly 134, and pumpflow tube 152 back through the pump and into the reservoir 131 until thenext dispensing action. Advantageously, this clears the dispensingsystem, thereby preventing or minimizing food substance clogs in thedispensing flow path components.

The temperature sensor 193 and control circuitry 126 will continuouslymonitor the actual temperature of the liquid in the reservoir 131 duringthe dispensing cycle while the dispensing unit is in use. When theliquid cools to second preprogrammed minimum dispensing temperature(e.g. 113 degrees F. in one non-limiting example) lower than thepreprogrammed baseline operating temperature, the control circuitry 126may trigger the dispensing unit status lights 198 to light flashing“RED.” This is a visual indication or hint to the user that thedispensing unit 102 should be placed back on the charging base 104 toreheat the food substance to the baseline operating temperature.Maintaining the temperature of the liquid food substance (e.g. butter)in the reservoir

A timer circuit may be incorporated in the control circuitry 126 whichincludes a preprogrammed time limit. If the time limit is reached andthe control circuitry does not sense that the user has not re-engagedthe dispensing unit 102 with the base 104, the control circuitryautomatically shuts the dispensing unit off to prevent clogging thedispensing tube or nozzle assembly.

In the foregoing process, it bears noting that the control circuitry 126of dispensing unit 102 was configured (i.e. preprogrammed) to initiatethe heating cycle for melting the at least partially solid foodsubstance only upon placement of the dispensing unit 102 onto thecharging base 104. The heating band 132 is thus electrically powered viaelectrical connection to the base 104. This advantageously conserves theruntime of the onboard rechargeable battery 101 in the dispensing unit102 for pumping/spraying the food substance and operation of the statuslights 198 and temperature sensor 193 after the dispensing unit has beenseparated from the base 104. In other possible arrangements, the controlcircuitry 126 may be configured to also energize the heating band 132when the dispensing unit 102 is removed from the base to maintain thetemperature of the food substance in a liquid form. It is evident to oneskilled in the art that numerous control and operating variations arethus possible.

Advantages of the present dispensing system include the following. Thefilter in the pump intake fluid coupling assembly, such as for example ahole with a diameter of 0.1 mm can filter large particles such as buttergrease into the butter spraying system. The heating system heats thebutter to the desired minimum baseline operating temperature (e.g. 140degrees F. for butter) and keeps at a constant temperature. The heaterband 132 heats the pump dispensing tubing 160 and maintains thepreprogrammed minimum baseline operating temperature, which makes surethat the butter in the dispensing tubing is and remains fully melted inliquid form. The resilient and flexible structure of the heating bandmaintains conformal contact with substantially the entirety of thereservoir to even heat and maintain the temperature of the liquefiedbutter. The dispensing nozzle assembly 134 is heated through the heatconduction from the pump dispensing tubing 160 to prevent the butterfrom solidifying and clogging inside. The peristaltic pump motor 154automatically reverses after the butter stops spraying, which evacuatesresidual liquefied butter from the dispensing tube 160, dispensingnozzle assembly 134, and pump flow tube 152 which is pumped back to thereservoir 131 to prevent clogs in the dispensing system and reduce theresidues inside for preventing bacterial contamination betweencleanings. By intelligently monitoring the temperature of the liquefiedbutter within the dispensing unit 102 during use via the controlcircuitry 126 (which temperature corresponds directly to the viscosityof the butter), the control circuitry controls the pump so that the pumpmotor 154 responds to the spraying function only after the butter is ina completely melted state and in an appropriate temperature andviscosity level or range for dispensing which prevents clogs.

While the foregoing description and drawings represent some examplesystems, it will be understood that various additions, modifications andsubstitutions may be made therein without departing from the spirit andscope and range of equivalents of the accompanying claims. Inparticular, it will be clear to those skilled in the art that thepresent invention may be embodied in other forms, structures,arrangements, proportions, sizes, and with other elements, materials,and components, without departing from the spirit or essentialcharacteristics thereof. In addition, numerous variations in themethods/processes described herein may be made. One skilled in the artwill further appreciate that the invention may be used with manymodifications of structure, arrangement, proportions, sizes, materials,and components and otherwise, used in the practice of the invention,which are particularly adapted to specific environments and operativerequirements without departing from the principles of the presentinvention. The presently disclosed embodiments are therefore to beconsidered in all respects as illustrative and not restrictive, thescope of the invention being defined by the appended claims andequivalents thereof, and not limited to the foregoing description orembodiments. Rather, the appended claims should be construed broadly, toinclude other variants and embodiments of the invention, which may bemade by those skilled in the art without departing from the scope andrange of equivalents of the invention.

1. A system for heating and dispensing a food substance in a liquidstate comprising: a dispensing unit comprising: an elongated housingdefining a longitudinal axis; a reservoir disposed in the housing andconfigured for receiving a food substance; an arcuately curved heatingband complementary configured to the reservoir and in conformal contactwith exterior side surfaces of the reservoir, the heating band operableto melt the food substance therein to produce a liquid; the heating bandextending for substantially an entire height of the reservoir andwrapping around a circumference of the reservoir; a pump in fluidcommunication with the reservoir for pumping the liquid; a power supply;an actuator configured to selectively activate the pump; a dispensingnozzle supported by the housing; and a dispensing tube fluidly couplingthe pump to dispensing nozzle; wherein activating the pump dispenses theliquid from the reservoir through the dispensing tube and nozzle.
 2. Thesystem according to claim 1, wherein the heating band has a monolithicsolid structure extending between a top end and a bottom end of theheating band.
 3. The system according to claim 2, wherein the heatingband has a resiliently deformable structure with elastic memory and avertical slit extending between the top and bottom ends of heating band,the heating band having an undeformed diameter slightly smaller than thereservoir, and wherein the heating band changeable between an undeformedcontracted state and a deformed expanded state when positioned on thereservoir.
 4. The system according to claim 3, wherein the reservoircomprises a vertically elongated cylindrical shell having an open topfor inserting the food substance into the reservoir.
 5. The systemaccording to claim 1, wherein the dispensing tube extends verticallyfrom the pump to the dispensing nozzle and is disposed between thehousing and heating band.
 6. The system according to claim 5, whereinthe dispensing tube is L-shaped comprising a vertical section in contactwith the heating band which heats the dispensing tube and a shorterhorizontal section fluidly coupled to the nozzle.
 7. The systemaccording to claim 3, wherein the top end of heating band terminates ata point at least equal to or higher than a horizontal section of thedispensing tube.
 8. The system according to claim 1, wherein the pump isalterable between a normal operating direction which dispenses theliquid from the reservoir, and a reverse operating direction which drawsthe liquid from the dispensing tube back into the reservoir to clean thedispensing tube and prevent clogs.
 9. The system according to claim 8,wherein the pump is a peristaltic pump comprising at least one rotatingelement engageable with a U-shaped flexible pump tube fluidly coupledbetween the reservoir and dispensing tube.
 10. The system according toclaim 1, wherein the pump comprises a pump cover attached to a bottomend of the reservoir and having an intake port fluidly coupling thereservoir to the pump.
 11. The system according to claim 1, wherein thepower supply is a rechargeable battery.
 12. The system according toclaim 11, further comprising a charging base configured for removablymounting the dispensing unit to the base, the base operable to rechargethe battery.
 13. The system according to claim 1, further comprising atemperature sensor operable to measure a temperature of the liquid inthe reservoir and control circuitry communicably coupled to thetemperature sensor, wherein the control circuitry is configured suchthat the pump cannot be activated until the temperature reaches apreprogrammed minimum baseline operating temperature.
 14. The systemaccording to claim 1, further comprising a removable top coverdetachably coupled to the housing.
 15. A dispensing system for heatingand dispensing a food substance in a liquid state comprising: a housingdefining a longitudinal axis; a reservoir disposed in the housing andconfigured for receiving a food substance; a heater in thermal contactwith the reservoir and operable to melt the food substance therein toproduce a liquid; a pump in fluid communication with the reservoir forpumping the liquid; a power supply; an actuator configured toselectively activate the pump, the actuator being alterable between anactuated and a deactuated state; a dispensing nozzle supported by thehousing; a dispensing tube fluidly coupling the pump to the dispensingnozzle; a temperature sensor operable to measure a temperature of theliquid in the reservoir; and control circuitry operably coupled to thetemperature sensor and pump; wherein placing the actuator in an actuatedstate activates the pump and dispenses the liquid from the reservoirthrough the dispensing tube and nozzle; wherein the control circuitry isconfigured such that the pump cannot be activated until the temperaturereaches a preprogrammed minimum baseline operating temperature.
 16. Thesystem according to claim 15, wherein the control circuitry isconfigured such moving the actuator from the actuated state to thedeactauted state automatically reverses direction of the pump whichdraws the liquid from the dispensing tube back into the reservoir toclean the dispensing tube and prevent clogs.
 17. The system according toclaim 15, wherein the heater is in thermal contact with a majority ofthe dispensing tube to heat the tube for preventing the liquid fromsolidifying.
 18. A method for heating and dispensing a food substance ina liquid state, the method comprising: providing a dispensing unitcomprising a housing, a reservoir for receiving a food substance in atleast partially solid form, a heating band, a pump fluidly coupled tothe reservoir, and control circuitry operably coupled to the pump andheating band; inserting the food substance into the reservoir; heatingthe food substance with the heating band to produce a liquid; measuringa temperature of the liquid with a temperature sensor operably coupledto the control circuitry; depressing an actuator on the dispensing unit;activating the pump which rotates in a first direction; and the pumpdispensing the liquid from the reservoir through a dispensing tube;wherein the control circuitry is configured to prevent activating thepump until the temperature reaches a minimum baseline operatingtemperature preprogrammed into the control circuitry.
 19. The methodaccording to claim 18, further comprising: releasing the actuator; thecontrol circuitry sensing release of the actuator and automaticallyreversing direction of the pump in a second direction; drawing liquidfrom the dispensing tube back into the reservoir via the pump.
 20. Themethod according to claim 18, wherein the heating band is in directcontact with the dispensing tube, and further comprising a step ofheating the dispensing tube with the heating band to prevent clogs. 21.The method according to claim 18, wherein the control circuitry isconfigured to automatically turn the dispensing unit off when thetemperature of the liquid falls to a second preprogrammed minimumdispensing temperature lower than the minimum baseline operatingtemperature.